(/qs3/pubsys2/xml/en/manual/3666087/3666087-titlepage.

html)

Initial Check
This procedure covers both rear gear train engines and front
gear train engines.
Prior to starting this procedure, make sure
there is adequate clearance to remove the camshaft from the
rear of the engine
for rear gear train engines and from the
front of the engine for front gear train engines.
Clearance from Front/Rear Gear Housing
mm in

4 Cylinder 60.96 MIN 24

6 Cylinder 81.28 MIN 32

Note
: It may be necessary to remove original
equipment manufacturer (OEM) components
(radiator, charge-air cooler assembly, etc.)
for access.
Refer to the OEM instructions.
If adequate clearance can not be obtained, the engine must
be removed.

Preparatory Steps
Rear Gear Train
Batteries can emit explosive gases. To reduce the possibility
of personal injury, always ventilate the compartment before
servicing the batteries. To reduce the possibility of arcing,
remove the negative (-) battery cable first and attach the
negative (-) battery cable last.
Support the rear of the engine
using the rear support attached to the rear of the cylinder
block. Failure to support the engine
can cause personal injury.

Note
: The camshaft must be removed from the
flywheel end of the engine.
 Disconnect the batteries.
Remove the transmission and all related components, if
equipped. Refer to the OEM service manual.
Remove the flywheel. Refer to Procedure 016-005 in
Section 16. (/qs3/pubsys2/xml/en/procedures/40/40-
016-005-tr.html)
Remove the flexplate. Refer to Procedure 016-004 in
Section 16. (/qs3/pubsys2/xml/en/procedures/40/40-
016-004-tr.html)
Remove the flywheel housing. Refer to Procedure 016-
006 in Section 16
(/qs3/pubsys2/xml/en/procedures/40/40-016-006-
tr.html)
Remove the fuel lift pump. Refer to Procedure 005-045
in Section 5 (/qs3/pubsys2/xml/en/procedures/40/40-
005-045.html)
Remove the rocker lever cover. Refer to Procedure 003-
011 in Section 3
(/qs3/pubsys2/xml/en/procedures/40/40-003-011-
tr.html)
Remove the rocker levers. Refer to Procedure 003-008 in
Section 3 (/qs3/pubsys2/xml/en/procedures/40/40-
003-008-tr.html)
Remove the push rods. Refer to Procedure 004-014 in
Section 4 (/qs3/pubsys2/xml/en/procedures/40/40-
004-014-tr.html)
Raise the tappets. Refer to Procedure 004-015 in
Section 4. (/qs3/pubsys2/xml/en/procedures/40/40-
004-015-tr.html)
Lock the fuel pump. Refer to Procedure 005-014 in
Section 5 (/qs3/pubsys2/xml/en/procedures/40/40-
005-014-tr.html).

Note
: Failure to lock the fuel pump may result in
improper fuel pump timing during reassembly.

Front Gear Train

Batteries can emit explosive gases. To reduce the possibility
of personal injury, always ventilate the compartment before
servicing the batteries. To reduce the possibility of arcing,
remove the negative (-) battery cable first and attach the
negative (-) battery cable last.
Note
: The camshaft must be removed from the
vibration damper end of the engine.

 Disconnect the batteries.

Remove the rocker lever cover. Refer to Procedure 003-
011 in Section 3.
(/qs3/pubsys2/xml/en/procedures/40/40-003-011-
tr.html)
Remove the rocker levers. Refer to Procedure 003-008 in
Section 3. (/qs3/pubsys2/xml/en/procedures/40/40-
003-008-tr.html)
Remove the push rods. Refer to Procedure 004-014 in
Section 4. (/qs3/pubsys2/xml/en/procedures/40/40-
004-014-tr.html)
Remove the fuel lift pump. Refer to Procedure 005-045
in Section 5. (/qs3/pubsys2/xml/en/procedures/40/40-
005-045.html)
Remove the drive belt. Refer to Procedure 008-002 in
Section 8. (/qs3/pubsys2/xml/en/procedures/40/40-
008-002-tr.html)
Remove the fan hub, if required. Refer to Procedure 008-
039 in Section 8.
(/qs3/pubsys2/xml/en/procedures/40/40-008-039-
tr.html)
Remove the vibration damper. Use the following
procedure, if equipped with a viscous damper. Refer to
Procedure 001-052 in Section 1.
(/qs3/pubsys2/xml/en/procedures/40/40-001-052-
tr.html)
Remove the vibration damper. Use the following
procedure, if equipped with a rubber damper. Refer to
Procedure 016-004 in Section 16.
(/qs3/pubsys2/xml/en/procedures/40/40-016-004-
tr.html)
Remove the front gear cover. Refer to Procedure 001-
031 in Section 1
(/qs3/pubsys2/xml/en/procedures/40/40-001-031-
tr.html)
Raise the tappets. Refer to Procedure 004-015 in
Section 4 (/qs3/pubsys2/xml/en/procedures/40/40-
004-015-tr.html)

Remove
Rear Gear Train
 Note
: The engine can have either a mark on the
crankshaft gear or a chamfered tooth.
Rotate the engine to align the timing marks on the camshaft
and crankshaft gear.
Service Tip: The engine can be rotated by
installing two of the flywheel/flexplate mounting capscrews
half way. Then use a
pry bar in between the two capscrews to
rotate the engine.
Service Tip: Engines equipped with air

compressors may require the air compressor be timed to the

engine. To make sure that
the air compressor is properly
timed when the camshaft gear is later installed, scribe an
alignment line on the air compressor
and camshaft gear
before removing the camshaft gear.

On engines equipped with an air compressor/accessory drive,

it may be necessary to loosen/remove some of the air
compressor/accessory
drive mounting hardware in order to
remove the camshaft gear. It is not necessary to remove the
air compressor/accessory drive completely.
Loosening/removing some of the air compressor/accessory
drive mounting hardware will give enough clearance to

remove the camshaft

gear.
Loosen the air compressor
mounting fasteners (1).
Remove the two capscrews securing
the air compressor support (2).
If equipped with a hydraulic
pump driven off of the air compressor, it may be necessary to
remove and/or loosen some or all
of the mounting fasteners.
Refer to the OEM instructions.

Remove the camshaft gear capscrews and remove the

camshaft gear.
Refer to Procedure 001-012 in Section 1
(/qs3/pubsys2/xml/en/procedures/40/40-001-012-tr.html).

Note
: On engines equipped with an air
compressor/accessory drive, it may be necessary to
remove the air compressor/accessory drive
to gain
clearance to remove the camshaft gear.

Remove the thrust plate capscrews and remove the thrust

plate.

The camshaft will drop once the camshaft clears the last
bushing if not supported. This can cause damage to the
camshaft journal
or, if equipped, the camshaft speed indicator
ring.
Use a gear puller, service tool part number ST647, or
equivalent, to attach to the end of the camshaft where the
camshaft
gear mounts, to act as a handle. This will give
proper leverage and make it easier to remove the camshaft.

Slide the camshaft out of the bore using the installed gear
puller.

Front Gear Train

Use barring tool, Part Number 3824591, to rotate the
crankshaft to align the crankshaft to the camshaft gear timing
marks.

Remove the capscrews from the thrust plate.

Remove the
thrust plate.

Remove the camshaft and camshaft gear as an assembly.

Note
: Rotate the camshaft as it is being removed.
Use extreme care to make sure that the bushings are
not damaged during this process.

Disassemble
Front Gear Train
Remove the camshaft gear and locating key. Refer to
Procedure 001-013 in Section 1
(/qs3/pubsys2/xml/en/procedures/40/40-001-013.html).

Clean and Inspect for Reuse

Inspect the camshaft gear.
For rear gear train engines, Refer
to Procedure 001-012 in Section 1
(/qs3/pubsys2/xml/en/procedures/40/40-001-012-tr.html).
For front gear train engines, Refer to Procedure 001-013 in
Section 1 (/qs3/pubsys2/xml/en/procedures/40/40-001-
013.html).

Inspect the camshaft bushing. Refer to Procedure 001-010 in

Section 1 (/qs3/pubsys2/xml/en/procedures/40/40-001-010-
tr.html).

Note
: Front gear train engines will have a front
camshaft bushing. Rear gear train engines will have a
rear camshaft bushing. Some
engines may be
equipped with both.

Only inspect the camshaft bushing that is on the same end of

the engine from which the camshaft was removed.
Note
: Inspection of the rest of the camshaft
bushings and camshaft block bores is not necessary
unless, during the inspection of the camshaft,
damage was noted on the camshaft journals.

When using solvents, acids, or alkaline materials for cleaning,

follow the manufacturer's recommendations for use. Wear
goggles
and protective clothing to reduce the possibility of
personal injury.
Wear appropriate eye and face protection
when using compressed air. Flying debris and dirt can cause
personal injury.
Clean the camshaft with solvents and dry with
compressed air.

Inspect the valve lobes and bearing journals for cracking,

pitting, or scoring.
Inspect the camshaft gear mounting
surface on the camshaft to ensure the camshaft gear locating
dowel pin is in place and
not bent, sheared, or cracked.

See Service Bulletin 3666475, Camshaft and Tappet Reuse

Guidelines, for reuse guidelines for cast iron camshafts.

Edge Deterioration (breakdown) Criteria

The area of edge
deterioration must not be greater than the equivalent area of a
2-mm [0.079-in] circle within ±20 degrees of the nose of the
camshaft lobe.

Outside of the ±20 degrees of the nose of the camshaft lobe,

the areas of edge deterioration must not be greater than the
equivalent area of a 6-mm [0.236-in] circle.

Note
: If the camshaft shows any pitting or wear,
remove and inspect the tappets before installing the
camshaft. Refer to Procedure 004-015 in Section 4
(/qs3/pubsys2/xml/en/procedures/44/44-004-

015.html). If a new camshaft is installed, new tappets

and push rods must be installed also.

Measure
Measure the peak of the camshaft valve lobes.
4 Cylinder (Rear Gear Train) Diameter of Peak of
Lobe
mm in
Intake 46.132 MIN 1.8162
 Exhaust 45.632 MIN 1.797

4 Cylinder (Front Gear Train) Engine Peak of Lobe

Diameter by Camshaft Part Number
Minimum
Part Number Minimum Intake
Exhaust

  mm [in] mm [in]
3929039 45.400 [1.787] 45.141 [1.777]
3925582 45.400 [1.787] 45.141 [1.777]
3914638 45.400 [1.787] 45.141 [1.777]
3929885 45.795 [1.803] 44.649 [1.758]
3929038 45.795 [1.803] 44.166 [1.739]
3924574 45.795 [1.803] 44.166 [1.739]
3931281 45.400 [1.787] 44.649 [1.758]
3930346 45.400 [1.787] 44.649 [1.758]
6 Cylinder (Front Gear Train) Engine Peak of Lobe
Diameter by Camshaft Part Number
Minimum
Part Number Minimum Intake
Exhaust
  mm [in] mm [in]
3283179 45.795 [1.803] 44.649 [1.758]
3929734 45.795 [1.803] 45.141 [1.777]
3929040 45.795 [1.803] 45.141 [1.777]
3926671 45.795 [1.803] 45.141 [1.777]
3924109 45.258 [1.782] 45.141 [1.777]
3929041 45.400 [1.787] 45.141 [1.777]
3921953 45.400 [1.787] 45.141 [1.777]
3930469 45.400 [1.787] 45.141 [1.777]
3919608 45.400 [1.787] 45.141 [1.777]
3929042 45.400 [1.787] 45.141 [1.777]
3914639 45.400 [1.787] 45.141 [1.777]
3929886 45.795 [1.803] 44.649 [1.758]
3930378 45.400 [1.787] 44.649 [1.758]
3283179 45.795 [1.803] 44.649 [1.758]

Measure the camshaft bearing journals.

Journal Diameter
mm in
 Journal Diameter
mm in
53.962 MIN 2.1245
54.013 MAX 2.1265

Measure the fuel transfer pump lobe:

Fuel Transfer Pump Lobe Diameter
mm in
35.50 MIN 1.398
36.26 MAX 1.428

Measure the camshaft thrust plate thickness:

Rear Gear Train Camshaft Thrust Plate Thickness
mm in
5.25 MIN 0.207
5.35 MAX 0.211

Front Gear Train Camshaft Thrust Plate Thickness

mm in
9.40 MIN 0.370
9.60 MAX 0.378

If the camshaft thrust plate is out of specification, replace the

thrust plate.

Note
: Front Gear Train and Rear Gear Train engines
do not use the same camshaft thrust plate. The
camshaft thrust plate thickness can also be verified
by checking camshaft end play
during installation.

Assemble
Front Gear Train
Install the camshaft gear locating key and camshaft gear.
Refer to Procedure 001-013 in Section 1
(/qs3/pubsys2/xml/en/procedures/40/40-001-013.html).

Install
Rear Gear Train
Apply assembly lubricant, Part Number 3163087, to the rear
camshaft bore.

Lubricate the camshaft lobes, journals, and thrust washer with

assembly lubricant, Part Number 3163087.

Use a gear puller, service tool Part Number ST647, or

equivalent, to attach to the end of the camshaft where the
camshaft
gear mounts, to act as a handle. This will give
proper leverage and ease installing the camshaft.

Do not force the camshaft into the camshaft bore as damage

to the camshaft bushing can result.
Install the camshaft.
While pushing in slightly, rotate the camshaft and carefully
work the camshaft through the camshaft
bushings. As each
camshaft journal passes through a bushing, the camshaft will
drop slightly and the camshaft lobes will catch
on the

bushings. Rotating the camshaft will free the lobe from the
bushing and allow the camshaft to be installed.

Install the thrust plate.

Install the thrust plate capscrews.
Torque Value:  24 
n•m
  
[
212 in-lb
]

To reduce the possibility of engine damage, make sure the

camshaft rotates freely.
Note
: The engine can have either a mark on the
crankshaft gear or a chamfered tooth.
Align the timing marks on the camshaft gear with the timing
marks on the crankshaft gear.

Note
: If equipped with an air compressor, make sure
to align the line that was scribed on the camshaft
gear and air compressor
gear during the camshaft
gear removal step. Refer to Procedure 012-014 in
section 12.
(/qs3/pubsys2/xml/en/procedures/40/40-012-014-
tr.html)If this was not done.

Rotate the camshaft so that the camshaft dowel pin aligns

with the slot on the camshaft gear. Install the camshaft gear
and
capscrews.
Tighten the capscrews.
Torque Value:  36 
n•m
  
[
27 ft-lb
]

Use gauge, Part Number 3824564, and magnetic base, Part

Number 3377399, to verify the camshaft has proper backlash
and end
clearance.
Camshaft End Play (A)
mm in
0.10 MIN 0.004

0.36 MAX 0.014

Camshaft Gear Backlash Limits (B)

 mmCamshaft Gear Backlash Limits (B) in

mm in
0.076 MIN 0.003
0.280 MAX 0.011

Front Gear Train

Apply assembly lubricant, Part Number 3163087, to the front
camshaft bore.

Lubricate the camshaft lobes, journals, and thrust plate with

assembly lubricant, Part Number 3163087.

Do not try to force the camshaft into the camshaft bore as

damage to the camshaft bushing can result.
Install the
camshaft. While pushing in slightly, rotate the camshaft and
carefully work the camshaft through the camshaft
bushings.
As each camshaft journal passes through a bushing, the
camshaft will drop slightly and the camshaft lobes will catch
on the bushings. Rotating the camshaft will free the lobe from

the bushing and allow the camshaft to be installed.

To reduce the possibility of engine damage, make sure the

camshaft rotates freely.
Before the camshaft gear engages
the crankshaft gear, check the camshaft for ease of rotation.
When installed properly, the
camshaft must rotate freely.

Align the timing marks as illustrated and finish installing the

camshaft.

Install the thrust plate.

Install the thrust plate capscrews.
Torque Value:  24 
n•m
  
[
18 ft-lb
]

Use gauge, Part Number 3824564, and magnetic base, Part

Number 3377399, to verify the camshaft has proper backlash
and end
clearance.
Camshaft End Play (A)
mm   in
0.12 MIN 0.005

0.47 MAX 0.018

Camshaft Gear Backlash Limits (B)
mm   in
0.076 MIN 0.003
0.280 MAX 0.011

Finishing Steps
Rear Gear Train
Batteries can emit explosive gases. To reduce the possibility
of personal injury, always ventilate the compartment before
servicing the batteries. To reduce the possibility of arcing,
remove the negative (-) battery cable first and attach the
negative (-) battery cable last.
Unlock the fuel pump. Refer to Procedure 005-014 in
Section 5 (/qs3/pubsys2/xml/en/procedures/40/40-

005-014.html).
 Lower the tappets. Refer to Procedure 004-015 in
Section 4 (/qs3/pubsys2/xml/en/procedures/40/40-
004-015-tr.html)
Install the push rods. Refer to Procedure 004-014 in
Section 4 (/qs3/pubsys2/xml/en/procedures/40/40-
004-014-tr.html)
Install the rocker levers. Refer to Procedure 003-008 in
Section 3 (/qs3/pubsys2/xml/en/procedures/40/40-
003-008-tr.html)
Adjust the valve lash. Refer to Procedure 003-004 in
Section 3 (/qs3/pubsys2/xml/en/procedures/40/40-
003-004-tr.html)
Install the rocker lever cover. Refer to Procedure 003-
011 in Section 3
(/qs3/pubsys2/xml/en/procedures/40/40-003-011-
tr.html)
Install the fuel lift pump. Refer to Procedure 005-045 in
Section 5 (/qs3/pubsys2/xml/en/procedures/40/40-
005-045.html).
Install the flywheel housing. Refer to Procedure 016-006
in Section 16 (/qs3/pubsys2/xml/en/procedures/40/40-
016-006-tr.html)
Install the flywheel. Refer to Procedure 016-005 in
Section 16 (/qs3/pubsys2/xml/en/procedures/40/40-
016-005-tr.html)
Install the flexplate. Refer to Procedure 016-004 in
Section 16. (/qs3/pubsys2/xml/en/procedures/40/40-
016-004-tr.html)
Install the transmission and all related components, if
equipped. Refer to the OEM service manual.
Install the air compressor. Refer to Procedure 012-014 in
Section 12. (/qs3/pubsys2/xml/en/procedures/40/40-
012-014-tr.html)
Connect the batteries
Operate the engine and check for leaks.

Front Gear Train

Batteries can emit explosive gases. To reduce the possibility
of personal injury, always ventilate the compartment before
servicing the batteries. To reduce the possibility of arcing,
remove the negative (-) battery cable first and attach the
negative (-) battery cable last.
Install the front gear cover. Refer to Procedure 001-031
in Section 1 (/qs3/pubsys2/xml/en/procedures/40/40-

 001-031-tr.html)
Install the vibration damper. Use the following
procedure, if equipped with a viscous damper. Refer to
Procedure 001-052 in Section 1
(/qs3/pubsys2/xml/en/procedures/40/40-001-052-
tr.html).
Use the following procedure, if equipped with a rubber
damper. Refer to Procedure 016-004 in Section 1.
(/qs3/pubsys2/xml/en/procedures/40/40-016-004-
tr.html)
Release the tappets. Refer to Procedure 004-015 in
Section 4 (/qs3/pubsys2/xml/en/procedures/40/40-
004-015-tr.html)
Install the push rods. Refer to Procedure 004-014 in
section 4 (/qs3/pubsys2/xml/en/procedures/40/40-
004-014-tr.html)
Install the rocker levers. Refer to Procedure 003-008 in
Section 3 (/qs3/pubsys2/xml/en/procedures/40/40-
003-008-tr.html)
Adjust the valve lash. Refer to Procedure 003-004 in
Section 3 (/qs3/pubsys2/xml/en/procedures/40/40-
003-004-tr.html)
Install the rocker lever cover. Refer to Procedure 003-
011 in Section 3
(/qs3/pubsys2/xml/en/procedures/40/40-003-011-
tr.html)
Install the fuel lift pump. Refer to Procedure 005-045 in
Section 5 (/qs3/pubsys2/xml/en/procedures/40/40-
005-045.html).
Install the fan hub, if required. Refer to Procedure 008-
039 in Section 8
(/qs3/pubsys2/xml/en/procedures/40/40-008-039-
tr.html)
Install the drive belt. Refer to Procedure 008-002 in
Section 8 (/qs3/pubsys2/xml/en/procedures/40/40-
008-002-tr.html).
Connect the batteries
Operate the engine and check for leaks.

Last Modified:  05-Aug-2016